Printing unit and manufacturing line for manufacturing flexible organic EL display

ABSTRACT

A printing unit include a plurality of ink supply members for supplying inks different from each other to a printing area or printing area-like portion, and a plurality of detecting systems, each detecting an amount of the corresponding ink accumulated on the printing area or printing area-like portion. A control system controls the plurality of ink supply members to regulate an amount of ink supplied by each of the plurality of ink supply members so as to bring the amount of the corresponding ink accumulated into agreement with a predetermined value

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.10/725,992 filed on Dec. 2, 2003. This application claims the benefit ofJapanese Patent Application 2002-350794 filed Dec. 3, 2002 and JapanesePatent Application 2002-350795 filed Dec. 3, 2002. The disclosures ofthe above applications are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the technical field of printing(coating) onto a web. Particularly, the present invention relates to aprinting unit and a manufacturing line for manufacturing a flexibleorganic electroluminescent (EL) display that make it possible to apply aplurality of colors to a web by a single passage of the web through asingle printing unit when printing ink of the same color (the same kind)in a pattern extending in a direction in which the web runs.

BACKGROUND ART

For example, the fabrication processes for an organic EL display includea process of applying organic EL light emitting layers in differentpatterns to a film specially processed to incorporate transparent orsemitransparent electrode(s). The patterns are stripes extending in adirection in which the film runs and provided by applying each ofregions isolated from each other in a lateral direction (a directionorthogonal to the direction in which the film runs) with one of inks fordifferent organic EL light emitting layers. For three organic EL lightemitting layers of different kinds, three inks of different kinds areapplied using a plurality of printing units corresponding to the numberof inks needed. A conventional method of coloring a film with threecolor inks requires three printing units for passage of the film throughthem one after another.

According to the prior art, accounting for the desired patterns oforganic EL light emitting layers requires printing, at three differenttimes, three laterally isolated regions of a film. Generally, the entireregions (the entire surface) of the film need to be printed one on topof an other, inevitably requiring comparatively uneconomical and bulkyequipment. Printing pressure acts three times on the film that isprocessed to include transparent or semitransparent electrode(s) aspressure acts on the film during transfer operation at three printingunits one after another. The repetitive application of pressure to thefilm may cause breakdown of the electrode(s) and limit emittingelement(s) involved. In other words, the repeated application ofprinting pressure causes an increase in ratio of risk that the speciallyprocessed portion and light emitting layer of the film may lose theirinherent characteristics.

SUMMARY OF THE INVENTION

The present invention has been devised to solve the above-mentionedproblem, and an object of the present invention is to provide a printingunit and a manufacturing line for a flexible organic EL display thatfeature simple equipment for applying inks of different kinds todifferent regions with small ratio of risk that the printed product maylose its inherent characteristic.

The present invention provides a printing unit comprising: at least oneprinting area or printing area-like portion; a plurality of ink supplymembers for supplying inks different, in kinds, from each other to theprinting area or printing area-like portion; a plurality of detectingsystems, each detecting an amount of the corresponding ink accumulatedon the printing area or printing area-like portion; and a control systemfor controlling the plurality of ink supply members to regulate anamount of ink supplied by each of the plurality of ink supply members soas to bring the amount of the corresponding ink accumulated intoagreement with a predetermined value established for the ink detected.

According to the present invention, the plurality of ink supply memberssupply inks different in kind, to at least one printing area orarea-like portion; there is a plurality of detecting systems, eachdetecting an amount of the corresponding ink accumulated on the printingarea or printing area-like portion; and a control system that controlsthe plurality of ink supply members to regulate an amount of inksupplied by each of the plurality of ink supply members in such a way asto bring the amount of the corresponding ink accumulated into agreementwith a predetermined value established for the ink detected. That is,with the one printing area, inks different in kind can be printed.Accordingly, the printing unit provided according to the presentinvention utilizes simple equipment for applying inks of different kindsto different regions with a small ratio of risk that the printed productmay lose its inherent characteristic.

According to the present invention, there is provided the printing unit,wherein the printing area or printing area-like portion is a part of agravure printing cylinder immediately upstream a doctor blade wiping anexcess ink off the gravure printing cylinder.

According to the implementation of the present invention, there isprovided, in gravure printing, a printing unit that can carry outprinting to the printing area with inks of different kinds, whichutilizes simple equipment and which has a small ratio of risk that theprinted product may lose its inherent characteristic.

According to the present invention, there is provided the printing unit,wherein the printing area or area-like portion is a part of an offsetgravure printing cylinder immediately upstream a doctor blade wiping anexcess ink off the offset gravure printing cylinder.

According to the present invention, there is provided, in gravure offsetprinting, a printing unit that can carry out printing to the printingarea with inks of different kinds, which utilizes simple equipment andwhich has a small ratio of risk that the printed product may lose itsinherent characteristic.

According to the present invention, there is provided the printing unit,wherein the printing area or printing area-like portion is a part of ananilox roller of flexo printing immediately upstream a doctor bladewiping an excess ink off the anilox roller.

According to the implementation of the present invention, there isprovided, in flexo printing, a printing unit that can carry out printingto the printing area with inks of different kinds, which utilizes simpleequipment and which has a small ratio of risk that the printed productmay lose its inherent characteristic.

According to the implementation of the present invention, there isprovided the printing unit, wherein the printing area or printingarea-like portion is an ink roller of offset printing.

According to the implementation of the present invention, there isprovided, in offset printing, a printing unit that can carry outprinting to the printing area with inks of different kinds, whichutilizes simple equipment and which has a small ratio of risk that theprinted product may lose its inherent characteristic.

According to the present invention, there is provided the printing unit,wherein the printing area or printing area-like portion is a part of ascreen printing plate immediately upstream a squeegee wiping an excessink off the screen printing plate.

According to the implementation of the present invention, there isprovided, in screen printing, a printing unit that can carry outprinting to the printing area with inks of different kinds, whichutilizes simple equipment and which has a small ratio of risk that theprinted product may lose its inherent characteristic.

According to the invention, there is provided the printing unit, whereineach of the plurality of ink supply members includes an ink container, apump to deliver the ink out of the container, and a nozzle to eject theink to the printing area or printing area-like portion.

According to the implementation of the present invention, the ink supplymembers send inks out of the ink containers by ink pumps to eject themout of nozzles toward the printing area or printing area-like portion.

According to the present invention, there is provided the printing unit,wherein each of the plurality of detecting systems includes adisplacement sensor for detecting a surface portion of the accumulatedink.

According to the implementation of the present invention, thedisplacement sensor detects the surface portion of the accumulated ink,and therefore the detecting can be easily carried out.

According to the present invention, there is provided the printing unit,wherein the control system controls a flow rate of the ink deliveredfrom the pump of each of the plurality of ink supply members to thenozzle so that the surface position of the ink is brought into agreementwith a predetermined level.

According to the implementation of the present invention, the controlsystem controls the ink pumps to regulate a discharge amount of inksupplied by each of the ink pumps. The discharge amount of ink suppliedby each of the ink pumps is regulated by controllably operating the inkpumps.

According to the present invention, there is provided a manufacturingline for manufacturing an organic EL display, comprising: a firstcoating unit for producing a processed printed film that includes aprinted film and an adhesive layer thereon formed by coating an adhesiveto the printed film; and a laminating unit for laminating a processedmulti-layered film including at least a barrier layer, a transparent orsemi-transparent electrode, and an insulating layer to the processedprinted film with automatic registration to produce a laminated film.

According to the present invention, the first coating unit produces aprocessed printed film that includes a printed film and an adhesivelayer thereon formed by coating an adhesive to the printed film; and alaminating unit that laminates a processed multi-layered film includingat least a barrier layer, a transparent or semi-transparent electrode,and an insulating layer to the processed printed film with automaticregistration to produce a laminated film. Accordingly, a manufacturingline is provided that meets demand for mass-production, provides goodyield and does not require any skilled labor.

According to the present invention, there is provided the manufacturingline, wherein the first coating unit includes a first feeder for feedinga film by unwinding the film from a first roll and a first printing unitfor printing an image to the film to produce the printed film.

According to the implementation of the present invention, at the firstfeeder, the film is fed by unwinding the film from the first roll and,at the first printing unit, the image is printed to the film to producethe printed film. Thus, the manufacturing line has an in-line processfor producing the printed film.

According to the present invention, there is provided the manufacturingline, further comprising a second feeder for feeding the processedmulti-layered film to the laminating unit by unwinding the processedmulti-layered film from a second roll.

According to the implementation of the present invention, at the secondfeeder, the processed multi-layered film is fed to the laminating unitby unwinding the processed multi-layered film from the second roll.Thus, the manufacturing line has an in-line process for producing theprocessed multi-layered film.

According to the present invention, there is provided the manufacturingline, further comprising a second coating unit for applying ahole-injection material to the laminated film from the laminating unitto form a hole-injection layer on the laminated film to produce ahole-injection layer coating film.

According to the implementation, the second coating unit applies thehole-injection material to the laminated film from the laminating unitto form the hole-injection layer on the laminated film to produce thehole-injection layer coating film. Thus, the manufacturing line has anin-line process for producing the hole-injection layer coating film.

According to the implementation of the present invention, there isprovided the manufacturing line, further comprising a second printingunit for applying an organic EL ink to the hole-injection layer coatingfilm to form a light emitting layer on the hole-injection layer coatingfilm to produce a light emitting layer coating film.

According to the implementation of the present invention, the secondprinting unit applies the organic EL ink to the hole-injection layercoating film to form the light emitting layer on the hole-injectionlayer coating film to produce the light emitting layer coating film.Thus, the manufacturing line has an in-line process for producing thelight emitting layer coating film.

According to the present invention, there is provided the manufacturingline, further comprising a cutting unit for cutting the light emittinglayer coating film to pieces of a desired dimension.

According to the implementation of the present invention, the cuttingunit cuts the light emitting layer coating film to pieces of the desireddimension. Thus, the manufacturing line has an in-line process forcutting the light emitting layer coating film to pieces of the desireddimension.

According to the implementation of the present invention, there isprovided the manufacturing line, wherein the second printing unitcomprises: at least one printing area or printing area-like portion; aplurality of ink supply members for supplying inks different, in kinds,from each other to the printing area or printing area-like portion; aplurality of detecting systems, each detecting an amount of thecorresponding ink accumulated on the printing area or printing area-likeportion; and a control system for controlling the plurality of inksupply members to regulate an amount of ink supplied by each of theplurality of ink supply members so as to bring the amount of thecorresponding ink accumulated into agreement with a predetermined valueestablished for the ink accumulated.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating one exemplary construction ofa printing unit according to the present invention.

FIG. 2 is a side view illustrating the one exemplary construction of theprinting unit according to the present invention.

FIG. 3 is a view illustrating one example of a printing product providedby the printing unit according to the present invention.

FIG. 4 is a view illustrating another example of a printing productprovided by the printing unit according to the present invention.

FIG. 5 is a view illustrating modifications of a printing unit accordingto the present invention.

FIG. 6 is a cross sectional view illustrating one example of a layeredstructure of a flexible organic EL display manufactured by amanufacturing line according to the present invention.

FIG. 7 is an explanatory view illustrating one example of constructionof a manufacturing line according to the present invention.

FIG. 8 is an explanatory view of process to produce a laminated filmwith automatic registration.

FIG. 9 is an explanatory view illustrating a conventional method formanually laminating films one on top of the other.

PREFERRED EMBODIMENTS OF THE INVENTION First Embodiment

Next, one embodiment according to the present invention is described.FIGS. 1 and 2 illustrate, as one example, the construction of a printingunit according to the present invention. In FIGS. 1 and 2, referencenumerals 1 a, 1 b and 1 c designate ink supply members, referencenumerals 2 a, 2 b and 2 c designate detecting systems, referencenumerals 3 a, 3 b and 3 c designate regulators of a control system,reference numeral 4 designates a printing cylinder, reference numeral 5designates a doctor blade, reference numeral 6 designates a compressioncylinder, reference numerals 10 a, 10 b and 10 c designate inks, andreference numeral 100 designates a web.

The ink supply members 1 a, 1 b and 1 c are arranged for supplying inks,which are different in color or kind from each other, to a printing areaor printing area-like portion. Each of the ink supply members 1 a, 1 band 1 c includes, for example, an ink container 11 containing ink, anink pump 12 to deliver the ink out of the container 11, and a nozzle 14to eject the ink to the printing area or printing area-like portion.This construction employs a control arrangement wherein the ink pump 12,which provides supply of ink, is put in ON or OFF duty alternately toregulate an amount of ink supplied by the corresponding one of the inksupply members 1 a, 1 b and 1 c.

Each of the ink supply members 1 a, 1 b and 1 c may include anelectromagnetic valve 13 between an ink pump 12 and the associatednozzle 14. The electromagnetic valve 13 is opened or closed alternatelyto regulate an amount of ink supplied by the corresponding one of inksupply members 1 a, 1 b and 1 c. In this case, it is necessary to feedink under pressure to the electromagnetic valve 13. Thus, the ink pump12 is activated to discharge ink under pressure. If desired, gravity maybe utilized to apply pressure to ink by elevating an ink container 11.In this case, the ink pump 12 may be eliminated from the unit.

In FIGS. 1 and 2, the printing area or printing area-like portion is apart 15 of a gravure printing cylinder 4 immediately upstream a doctorblade 5 wiping an excess ink off the printing cylinder 4. As theprinting cylinder 4 rotates in a direction as indicated by arrows (seeFIG. 2), the inks supplied to the above-mentioned part 15 by the inksupply members 1 a, 1 b and 1 c, respectively, are brought to a terminalsegment of the doctor blade 5 kept in contact with the printing cylinder4. Excess inks, which have failed to be received in gravure cells of theprinting cylinder 4, are stopped by the terminal segment of the doctorblade 5 and accumulated. An amount of each ink accumulated increases ifthe rate of supply of the ink exceeds the rate of consumption of the inkby the gravure cell, while it decreases if the rate of supply of the inkis less than the rate of consumption of the ink by the gravure cells.

In other modifications of a printing unit, as shown in FIGS. 5(a) to5(b), the printing area or printing area-like portion is a part of anoffset gravure printing cylinder 4 a immediately upstream a doctor blade5 a wiping an excess ink off the offset gravure printing cylinder 4 a,or a part of an anilox roller 4 b of flexo printing immediately upstreama doctor blade 5 b wiping an excess ink off the anilox roller 4 b, or anink roller 4 c of offset printing, or a part of a screen printing plate4 d immediately upstream a squeegee wiping an excess ink off the screenprinting plate 4 d. The printing area or printing area-like portion isherein used to mean a portion of any printing system, which portion canapply different inks directly or indirectly to a printing substrate atregions isolated from each other in a lateral direction (a directionorthogonal to the direction in which the printing substrate runs). Theprinting area or printing area-like portion is applicable to anyprinting system without any limitation.

Available as the ink roller 4 c of offset printing are rollers of aninking roller train, which includes, for example, an ink fountainroller, an ink metering roller, an ink distributing roller, and aninking roller. Accounting for printing conditions, an appropriate one ofthem is selected as the ink roller 4 c, to which the ink supply members1 a, 1 b and 1 c supply inks. Supplying inks to an ink distributingroller or an inking roller is preferable in order to prevent inks fromspreading in the lateral direction after resting on a printing cylinder.

The detecting systems 2 a, 2 b and 2 c are provided, each detecting anamount of the corresponding one of different inks 10 a, 10 b and 10 caccumulated on the printing area or printing area-like portion 15. Eachof the detecting systems 2 a, 2 b and 2 c is a displacement sensor fordetecting a surface position of the corresponding one of the accumulatedinks 10 a, 10 b and 10 c since the surface position indicates the amountof the corresponding ink accumulated. The surface position of each ofthe accumulated inks 10 a, 10 b and 10 c approaches to the correspondingone of the displacement sensors 2 a, 2 b and 2 c if the rate of supplyof the ink exceeds the rate of consumption of the ink by the gravurecells, while it goes away if the rate of supply of the ink is less thanthe rate of consumption of the ink by the gravure cells. Each of thedisplacement sensors 2 a, 2 b and 2 c provides, as an output, adisplacement signal indicative of a distance to the surface position ofthe corresponding one of the accumulated inks 10 a, 10 b and 10 c.

The displacement sensors 2 a, 2 b and 2 c are in the form of a laserdisplacement sensor. The laser displacement sensors project a beam ofvisible laser that creates a spot on the target surface. Reflected lightfrom the surface is viewed from an angle by a line scan camera and thedistance to the surface is computed, using triangulation method, fromthe image pixel data. Other types of displacement sensors likeultrasonic displacement sensors and electrostatic capacity typedisplacement sensors may be used. The present invention is not limitedby types of displacement sensors used.

The control system includes regulators 3 a, 3 b and 3 c and controls theplurality of ink supply members 1 a, 1 b and 1 c to regulate an amountof ink supplied by each of the plurality of ink supply members 1 a, 1 band 1 c in such a direction as to bring the amount of the ink detectedby the corresponding one of the plurality of detecting systems 2 a, 2 band 2 c into agreement with a predetermined value established for theink detected. The regulators of the control system 3 a, 3 b and 3 ccontrols the pumps 12 to regulate an amount of ink discharged by each ofthe pumps 12 in such a direction as to bring the surface position of theaccumulated ink into agreement with a predetermined surface positionestablished for the accumulated ink. Each of the regulators 3 a, 3 b and3 c receives the displacement signal indicative of distance to thetarget ink surface, detected by the corresponding one of the detectingsystems 2 a, 2 b and 2 c, to the corresponding one of the ink supplymembers 1 a, 1 b and 1 c. The regulators 3 a, 3 b and 3 c compute adeviation between the detected displacement and a predetermineddisplacement (target value), and carries out duty-ON and duty-OFF of theink pumps 12 or electromagnetic valves 13 of the ink supply members 1 a,1 b and 1 c when the deviation fails to reach the lower limit of anallowable range and when it exceeds the upper limit of the allowablerange respectively.

If a higher precision control than the ON/OFF control is necessary, eachof the regulators 3 a, 3 b and 3 c computes a control amount on thebasis of a PID control that includes at least one of a proportionalcontrol an integral control action, and a derivative control action.Based on the computed control amount, the driving speed of the ink pumps12 or the opening rate of the electromagnetic valves 13 of the inksupply members 1 a, 1 b and 1 c are regulated.

Next, the operation of printing unit is described. The start-upprocedure for printing is initiated by passing the web 100 over theentire path through the printing unit. In FIG. 2, the web 100 is passedthrough a clearance opened between the printing cylinder 4 and thecompression cylinder 6 by shifting the compression cylinder 6 to a restposition. Subsequently, the web 100 is interposed between the printingcylinder 4 and the compression cylinder 6 by shifting the compressioncylinder 6 to a work position in which the compression cylinder 6 ispressed so as to firmly engage with the printing cylinder 4 to applyprinting pressure to the web 100.

Next, the blade end of doctor blade 5 is brought into contact with theprinting area on the printing cylinder 4 by shifting the doctor bladefrom a rest position to a work position.

Next, the printing unit is put into operation. The web 100 is pulled andtensioned by rotation of the printing cylinder 4, the compressioncylinder 6, a pair of in-feed rollers (not shown) upstream of theprinting unit, and a pair of out-feed rollers (not shown) downstream ofthe printing unit.

Next, the ink supply members 1 a, 1 b and 1 c, the detecting systems 2a, 2 b and 2 c, and the control system including regulators 3 a, 3 b and3 c are operated. Initially, as no ink is accumulated between the doctorblade 5 and the printing cylinder 4, the ink supply members 1 a, 1 b and1 c supply inks to the printing area or printing area-like portion. Eachof the detecting systems 2 a, 2 b and 2 c detects an amount of thecorresponding ink accumulated. The control system including theregulators 3 a, 3 b and 3 c controls the plurality of ink supply members1 a, 1 b, 1 c to regulate an amount of ink supplied by each of theplurality of ink supply members 1 a, 1 b and 1 c in such a direction asto bring the amount of the ink accumulated into agreement with apredetermined value established for the ink accumulated.

Next, as the printing cylinder 4 rotates, the supplied inks 10 a, 10 band 10 c are allowed to fill in gravure cells within the printing area.Within the printing area of the printing cylinder 4, the gravure cellsoccupy three stripe-like regions extending in a direction in which theweb runs and located at different locations spaced from each other in alateral direction orthogonal to the direction in which the web runs.FIG. 1 shows three different inks 10 a, 10 b and 10 c filling thegravure cells, respectively.

Next, as the printing cylinder 4 rotate, the inks 10 a, 10 b and 10 care transferred to the web 100 where the web 100 is pressed into firmcontact with the printing cylinder 4 to print an image on the web 100.In accordance with a transfer rate, each of the gravure cells loses aportion, in mass, of the ink, causing a drop, in mass, of the inkremaining in the gravure cell. Three stripe-like printing patterns areprinted on the web 100 with different inks 10 a, 10 b and 10 c,respectively (see FIG. 3).

As the printing cylinder 4 is further rotated, the gravure cells returnto portions which have the accumulated inks, receiving the accumulatedinks to compensate for the drop in mass of ink remaining in the gravurecell. Printing of the image to the web 100 continues by repeating acycle of transfer of ink from each of the gravure cells to the web 100and supply of ink to the gravure cell to compensate for the drop lost bythe previous transfer.

As mentioned above, the supply of an amount of ink to each of thegravure cells takes place where the ink is accumulated, reducing theaccumulated amount of the ink. This reduction in the accumulated amountof each of the inks is detected by one of detecting systems 2 a, 2 b and2 c. This detected reduction is complemented for by ink supplied by oneof the supply members 1 a, 1 b and 1 c, which are controlled by thecontrol system including the regulators 3 a, 3 c and 3 d. The controlsystem regulates an amount of ink supplied by each of the plurality ofink supply members 1 a, 1 b and 1 c in such a direction as to bring theamount of the ink accumulated into agreement with a predetermined valueestablished for the ink accumulated.

The end procedure for printing is initiated by shifting the compressioncylinder 6 from the work position to the rest position. This opens theclearance between the printing cylinder 4 and the compression cylinder6, reducing the pressure applied to the web 100 to zero, bringing theprinting to an end.

The subsequent procedure step is to stop movement of the web 100,allowing the printing cylinder 4 to come to a halt. As the accumulatedamount of each of the inks is controlled, the accumulated amount of theink will not exceed the predetermined value upon and after stopping theprinting.

The next procedure step is to stop the ink supply members 1 a, 1 b and 1c, the detecting systems 2 a, 2 b and 2 c, and the control systemincluding the regulators 3 a, 3 b and 3 c.

The next procedure step is to shift the doctor blade from the workposition to the reset position, disengaging the blade end of the doctorblade 5 from the printing area of the printing cylinder 4.

The next procedure step is to clean the printing cylinder 4, doctorblade 5 and the like to wipe remaining ink off them.

The operation has been described. Next, the products printed by theprinting unit according to the present invention are described. FIG. 3shows an example of the printed products. FIG. 3 shows a printingproduct 101 resulting from one rotation of the printing cylinder 4. Theprinting product 101 has three striped-like printing patterns coloredwith inks 10 a, 10 b and 10 c, respectively. The inks 10 a, 10 b and 10c are supplied by the independent ink supply members 1 a, 1 b and 1 c togravure cells occupying independent regions within the printing surfaceof the printing cylinder 4, respectively. Thus, different kinds of inkmay be used as inks 10 a, 10 b and 10 c. In this manner, by passing theweb 100 through a single printing unit, the printing product 101(colored) can be produced using a plurality kinds of inks.

FIG. 4 shows another example of the printed products by the printingunit according to the present invention. FIG. 4 shows a printing product102 resulting from one rotation of the printing cylinder 4. The printingproduct 102 has different arrays ┌1, 2, 3, . . . ┘, ┌a, b, c, . . . ┘,and ┘A, B, C . . . ┌. These arrays are printed with different inks 10 a,10 b and 10 c, which are supplied by the independent ink supply members1 a, 1 b and 1 c to gravure cells occupying independent regions withinthe printing surface of the printing cylinder 4, respectively. Thus,different kinds of ink may be used as inks 10 a, 10 b and 10 c. In thismanner, by passing the web 100 through a single printing unit, theprinting product 102 (colored) can be produced using a plurality kindsof inks.

In the preceding description, the present invention was described alongwith its implementation. It will be apparent from the previousdescription that the printing units, which the present invention relatesto, should not be construed in a narrow interpretation only to printingunits used to print books. Generally, the term “coating” is used to meanforming a film without any pattern, while the term “printing” is used tomean forming a film with pattern (shadow). The printing units of thepresent invention, are printing units in a broad interpretation andinclude coating units in a broad interpretation, for example rollcoaters. In the implementation of the present invention, the printingunit is a unit forming a film with pattern, that is, a unit formingpatterns of different physical properties, which are spaced in a lateraldirection (orthogonal to a direction in which a web runs).

As will be understood from the preceding description, according to theimplementation of the present invention, there is provided a printingunit, which can carry out printing to at least one printing area withinks of different kinds, which is of simple equipment and which has asmall ratio of risk that the printed product may lose its inherentcharacteristic.

According to the implementation of the present invention, there isprovided, in gravure printing, the printing unit, which can carry outprinting to the printing area with inks of different kinds, which is ofsimple equipment and which has a small ratio of risk that the printedproduct may lose its inherent characteristic.

According to the implementation of the present invention, there isprovided, in gravure offset printing, the printing unit, which can carryout printing to the printing area with inks of different kinds, which isof simple equipment and which has a small ratio of risk that the printedproduct may lose its inherent characteristic.

According to the implementation of the present invention, there isprovided, in flexo printing, the printing unit, which can carry outprinting to the printing area with inks of different kinds, which is ofsimple equipment and which has a small ratio of risk that the printedproduct may lose its inherent characteristic.

According to the implementation of the present invention, there isprovided, in offset printing, the printing unit, which can carry outprinting to the printing area with inks of different kinds, which is ofsimple equipment and which has a small ratio of risk that the printedproduct may lose its inherent characteristic.

According to the implementation of the present invention, there isprovided, in screen printing, the printing unit, which can carry outprinting to the printing area with inks of different kinds, which is ofsimple equipment and which has a small ratio of risk that the printedproduct may lose its inherent characteristic.

According to the implementation of the present invention, the ink supplymembers send inks out of the ink containers by ink pumps to eject themout of nozzles toward the printing area or printing area-like portion.

According to the implementation of the present invention, the detectingsystems are displacement sensors that detect surface positions of theinks accumulated as the accumulation amounts of the inks, making it verysimple to measure the accumulation amounts of the inks.

According to the implementation of the present invention, the controlsystem includes the regulators for controlling the ink pumps to regulatea discharge amount of ink supplied by each of the ink pumps. Thedischarge amount of ink supplied by each of the ink pumps is regulatedby controllably operating the ink pumps.

Second Embodiment

With reference, next, to this implementation, the present invention isdescribed. FIG. 6 is a cross sectional view illustrating one example ofa layered structure of a flexible high polymer organic EL displaymanufactured by a manufacturing line according to the present invention.In FIG. 6, reference numeral 101A designates a film, reference numeral102A designates a printing layer, reference numeral 103A designates anadhesive layer, reference numeral 201A designates a film, referencenumeral 202A designates a barrier layer, reference numeral 203Adesignates a transparent electrode, reference numeral 204A designates aninsulating layer, reference numeral 301A designates a light emittinglayer (an electron transport layer, a light emitting layer, a holeinjection layer), reference numeral 302A designates a metal layer of alow work function material, reference numeral 303A designates anelectrode (transparent), reference numeral 304A designates an adhesivelayer, the reference numeral 305A designates a barrier layer, thereference numeral 306A designates a film.

Referring to FIG. 7, the manufacturing line according to the presentinvention for manufacturing the flexible high polymer organic EL displayof the above-mentioned configuration is described. FIG. 7 is anexplanatory view illustrating one example of construction of themanufacturing line according to the present invention. In FIG. 7,reference numeral 1A designates a first feeder, reference numeral 2Adesignates a first printing unit, reference numeral 3A designates afirst coating unit, reference numeral 4A designates a second feeder,reference numeral 5A designates a laminating unit, reference numeral 6Adesignates a second coating unit, reference numeral 7A designates asecond printing unit, and reference numeral 7A designates a cuttingunit. In FIG. 7, the reference numeral 100B designates a first roll, andthe reference numeral 200B designates a second roll. The first roll 100Bincludes a film 100A that constitutes one layer of the structure shownin FIG. 6. The second 200B includes a processed multi-layered film 200Athat constitutes one layer of the structure shown in FIG. 6 and includesthe film 201A, the barrier layer 202A, the transparent electrode 203A,and the insulating layer 204A.

The first feeder 1A feeds the film 100A to the first printing unit 2A byunwinding the film 100A from the first roll 100B. Although notillustrated in FIG. 7, it is preferred to equip the first feeder 1A witha support shaft supporting the first roll 100B, a mechanism applyingbrake or reverse torque to the support shaft supporting the first roll100B in order to apply tension to the film 100A, a pair of feed rollersdriven to rotate to send the film 100A interposed between them at apredetermined speed, and a dancer roller detecting tension on the film100A upon being supplied.

The first printing unit 2A prints an image to the printing layer 102A ofthe film 100A to produce a printed film 100C. When overprinting isnecessary, the number of printing units can be increased. The firstprinting unit 2A includes an ink pan 21, a finisher roller 22, a doctorblade 23, a printing cylinder 24, a compression cylinder 25, and a dryer26. Although it is in the form of a printing unit for gravure printingin FIG. 7 the first printing unit 2A may be a printing unit for otherprinting like offset printing or flexo printing.

The first coating unit 3A produces a processed printed film 100D byforming the adhesive layer 103A on the printed film 100C by coating anadhesive thereto. The first coating unit 3A includes three rollers 31,32 and 33. The roller 31 delivers coating liquid (adhesive) through itssurface to an adjustable clearance between the rollers 31 and 32 so thatthe flow rate of the coating liquid is regulated by the clearance of therollers 32 and 33, and then the coating liquid is transferred to theprinted film 100C that is positioned between to the rollers 32 and 33.Although, not shown in FIG. 6, the first coating unit 3A may have adryer to dry the film after the coating process if the coating liquidused contains solvent.

The second feeder 4A feeds a processed multi-layered film 200A to thelaminating unit 5A by unwinding the processed multi-layered film 200Afrom a second roll 200B. The processed multi-layered film 200A includesthe film 201A, the barrier layer 202A, the transparent electrode 203Aand the insulating layer 204A. Although not shown in FIG. 7, it ispreferred to equip the second feeder 4A with a support shaft supportingthe second roll 200B, a mechanism applying brake or reverse torque tothe support shaft supporting the second roll 200B in order to applytension to the processed multi-layered film 200A, a pair of feed rollersdriven to rotate to send the processed multi-layered film 200Ainterposed between them at a predetermined speed, and a dancer rollerdetecting tension on the multi-layered film 200A upon being supplied. Itis preferred to provide the laminating unit 5A with web-edge guide andthe second roll 200B with side-lay for lateral registration between theprocessed printed film 100D and the processed multi-layered film 200A.

The laminating unit 5A (laminator) laminates the processed printed film100D to the processed multi-layered film 200A with automaticregistration to produce a laminated film 100E. The laminating unit 5Aincludes a pair of rollers 54 and 55 that are designed to interposetherebetween the processed printed film 100D and the processedmulti-layered film 200A and then to thermally press one on top of theother into firm engagement with each other. Further, the laminating unit5A includes a mark sensor 51 for detecting registration mark 51A on theprocessed printed film 100D, a mark sensor 52 for detecting registrationmark (transparent insulating layer) 52A on the processed multi-layeredfilm 200A, and a registration controller 53. Although not shown in FIG.7, it is preferred to provide, as a regulator (an operator) forregistration control, a compensator roller and a tension adjuster in thepath for one of the processed printed film 100D and the processedmulti-layered film 200A. The laminating unit 5A will be described laterin more detail.

The second coating unit 6A applies a hole-injection material to thelaminated film 100E to form a hole-injection layer 301A thereon toproduce a hole-injection layer coating film 100F. In FIG. 7, the secondcoating unit 6A is of the spray coating type. The second coating unit 6Aincludes a spray-coating head 61, a roller 62 supporting the laminatedfilm 100E from the back to restrain the coating position, and a dryer63. It is not intended to limit the second coating unit 6A to one unitof the spray coating type, but the second coating unit 6A may take anycoating type in which the hole-injection material can be applied evenlyto the substrate, such as, die coating type, roll coating type andgravure coating type.

The second printing unit 7 applies a high polymer organic EL ink (calledalso as organic EL ink) to the hole-injection layer coating film 10OF toform a light emitting layer 301A thereon to produce a light emittinglayer coating film 100G. In order to emit three colors RGB (red, green,blue) for producing a flexible high polymer organic EL display, aplurality of light emitting layers 301A of different kinds need to beformed. In FIG. 7, the second printing unit 7A is in the form of aprinting unit whereby a plurality of light emitting layers 301A can beprinted. The second printing unit 7A may take the form of a printingunit for other printing like gravure printing, flexo printing, offsetprinting, gravure offset printing, and screen printing.

The second printing unit 7A includes ink supply members 71, a doctorblade 72, a printing cylinder 73, a compression cylinder 74 and a dryer75. The ink supply members 71 are arranged laterally with respect to theprinting cylinder 73 for supplying inks of different kinds,respectively, to printing area on the single printing cylinder 73. Thedoctor blade 72 is arranged to wipe excess inks off the printingcylinder 73, accumulating mass of inks between the doctor blade 72 andthe printing area on the printing cylinder 73. The second printing unit7A may take the form of the printing unit described in the firstembodiment in FIGS. 1-5. The second printing unit 7A includes detectingsystems, each detecting an amount of the corresponding one of inks ofdifferent kinds accumulated on the printing area, and a control systemfor controlling the plurality of ink supply members to regulate anamount of ink supplied by each of the plurality of ink supply members insuch a direction as to bring the amount of the ink accumulated intoagreement with a predetermined value established for the inkaccumulated. With the printing unit, inks of different kinds can beprinted to a single printing area.

The printing area on the printing cylinder 73 is formed with printingpatterns including stripes that are laterally spaced and extend in adirection in which the substrate runs. The hole-injection layer coatingfilm 100F is interposed between the printing cylinder 73 and thecompression cylinder 74 and has printing pressure applied thereto. Afterthe printing, it is dried within the dryer 75. The light emitting layercoating film 100G thus produced in the above-mentioned processes hasprinted stripe-like light emitting layers 301A of different kinds thatare laterally spaced and extend in the longitudinal direction.

A plurality of printing units corresponding in number to a plurality oflight emitting layers 301A of different kinds may be provided to printthe emitting layers 301A, respectively, without using the singleprinting unit.

If the light emitting layers 301A do not involve any electron transportlayer, a third coating unit is provided downstream the dryer 75 to coatthe light emitting layer coating film 100G with electron transportlayers.

The cutting unit 8A cuts the light emitting layer coating film 100G topieces of a desired dimension to produce sheets of the light emittinglayer coating film 100G. The cutting unit 8A may be of any of the wellknown types. The present invention is not limited by the kinds or typesof the cutting unit 8A.

In the preceding description, the manufacturing line for manufacturing aflexible high polymer organic EL display according to the presentinvention has been described.

Next, the laminating unit 5 is now described in detail. As describedbefore, the laminating unit 5A laminates the processed printed film 100Dto the processed multi-layered film 200A with automatic registration toproduce the laminated film 100E. For automatic registration, thelaminating unit 5A includes the mark sensor 51 for detectingregistration mark 51A on the processed printed film 100D, the marksensor 52 for detecting registration mark (transparent insulating layer)52A on the processed multi-layered film 200A, and a registrationcontroller 53.

FIG. 8 is an explanatory view of process to produce a laminated filmwith automatic registration. As shown in FIG. 8, when the processedprinted film 100D runs, the registration mark sensor 51 detectsregistration mark 51A on the processed printed film 100D. Theregistration mark 51A is printed when producing the printed film 100 cby printing. The registration mark sensor 51 that detects theregistration mark 51A on the processed printed film 100D may take theform of a well known optical mark sensor. The present invention is notlimited by kinds or forms of registration mark sensor 51.

When the electrode equipped film (or processed multi-layered film) 200Aruns, the registration mark sensor 52 detects registration mark 52A onthe electrode equipped film 200A. The registration mark 52A is patternedwhen patterning the transparent electrode layer 203A of the electrodeequipped film 200A. The registration mark 52A is transparent so that thewell known optical mark sensor cannot be used as the mark sensor 52 fordetecting the registration mark 52A of the electrode equipped film 200A.

As the registration mark sensor 52, a mark sensor of special kind andform only may be utilized. A sensor 52 having a sensing form ofmeasuring the film thickness of the transparent electrode layer 203A(0.02˜0.4 μm thick) can be used as the registration mark sensor 52.Because the transparent electrode absorbs light within a range of shortwavelengths of visible ray, an optical sensor that employs a specialform of detecting a measuring value difference between the transparentelectrode and the film substrate by limiting spectra wavelength ofprojected light and spectra sensitivity of a light receiving element tothe range of short wavelength, is also usable as the registration marksensor 52.

FIG. 8 shows a method according to the present invention for laminatingfilms with automatic registration using the above-mentioned resignationmark sensors. FIG. 9 shows a conventional method for manually laminatingfilms one on top of the other, which would be inevitably chosen ifregistration mark sensors are unavailable. In FIG. 9, a sheet-like film110 of the printed layer 110A is laminated to a sheet-like film 112including an EL light emitting layer 112A and resignation mark 112B toproduce a light emitting layer film 114.

Thus, according to the present invention, a manufacturing line isprovided, which meets demand for mass-production, provides good yieldand requires any skilled labor.

The manufacturing line according to the present invention can achieve anin-line process for producing a printed film.

The manufacturing line according to the present invention can achieve anin-line process of supplying a processed multi-layered firm.

The manufacturing line according to the present invention can achieve anin-line process of process of forming a hole-injection layer to producea hole-injection layer coating film.

The manufacturing line according to the present invention can achieve anin-line process of printing high polymer organic EL light emittingmaterial to form light emitting layers to produce a light emitting layercoating film.

The manufacturing line according to the present invention can achieve anin-line process of cutting the light emitting layer coating film intopieces of a predetermined dimension.

1-9. (canceled)
 10. A manufacturing line for manufacturing an organic ELdisplay, comprising: a first coating unit for producing a processedprinted film that includes a printed film and an adhesive layer thereonformed by coating an adhesive to the printed film; and a laminating unitfor laminating a processed multi-layered film including at least abarrier layer, a transparent or semi-transparent electrode, and aninsulating layer to the processed printed film with automaticregistration to produce a laminated film.
 11. The manufacturing lineaccording to claim 10, wherein the first coating unit includes a firstfeeder for feeding a film by unwinding the film from a first roll and afirst printing unit for printing an image to the film to produce theprinted film.
 12. The manufacturing line according to claim 10, furthercomprising a second feeder for feeding the processed multi-layered filmto the laminating unit by unwinding the processed multi-layered filmfrom a second roll.
 13. The manufacturing line according to claim 10,further comprising a second coating unit for applying a hole-injectionmaterial to the laminated film from the laminating unit to form ahole-injection layer on the laminated film to produce a hole-injectionlayer coating film.
 14. The manufacturing line according to claim 13,further comprising a second printing unit for applying an organic EL inkto the hole-injection layer coating film to form a light emitting layeron the hole-injection layer coating film to produce a light emittinglayer coating film.
 15. The manufacturing line according to claim 14,further comprising a cutting unit for cutting the light emitting layercoating film to pieces of a desired dimension.
 16. The manufacturingline according to claim 14, wherein the second printing unit comprises:at least one printing area or printing area-like portion; a plurality ofink supply members for supplying inks different, in kinds, from eachother to the printing area or printing area-like portion; a plurality ofdetecting systems, each detecting an amount of the corresponding inkaccumulated on the printing area or printing area-like portion; and acontrol system for controlling the plurality of ink supply members toregulate an amount of ink supplied by each of the plurality of inksupply members so as to bring the amount of the corresponding inkaccumulated into agreement with a predetermined value established forthe ink accumulated.